Packaging machine

ABSTRACT

There is disclosed a machine for assembling, end capping, and packaging together in a preselected manner, a plurality of rolls wherein each of the rolls includes a material having a preselected color and/or pattern wound thereon and wherein the axial edge of the outer convolution of material on each of the rolls is oriented in a preselected position within the finished package. In the preferred embodiment of the invention, the disclosed machine is used to assemble and end cap rolls of paper, such as Christmas gift wrap paper. The machine comprises a plurality of feed elements wherein each of the feed elements includes a receptacle for storing a plurality of rolls wherein the material on each of the rolls in any one feed element contains the same color and/or pattern of material wrapped thereon. The feed elements individually feed the rolls contained therein onto a conveyor means. The conveyer means transports these rolls which are now arranged in a preselected color and/or pattern orientation to a grouping means which divides the rolls into a plurality of groups of rolls wherein each of the groups contain a preselected number of rolls having a preselected pattern and/or color distribution. This grouping means then feeds the group of rolls to an orienting means which acts upon the rolls in the group and orients the axial edge of the material wound on each of the rolls such that the axial edge is hidden from view within the package. Lastly, the group of rolls is then transported to a capping station wherein caps are placed over the end portion of the rolls to form a single package of rolls.

United States Patent [191 Pnrdom et al.

[ PACKAGING MACHINE [75] Inventors: Clyde H. Purdom, Memphis, Tenn.;

Kenneth W. Allum, South Haven, Miss.; Harold D. Shackelford, Memphis, Tenn.

[73] Assignee: Cleo Wrap Corporation, Memphis,

Tenn.

[22] Filed: Nov. 2, 1973 [21] Appl. No.: 412,344

Related U.S. Application Data [62] Division of Ser. No. 290,845, Sept. 21, 1972, Pat.

Primary Examiner-Travis S. McGehee Attorney, Agent, or Firml-lune, Clement, Brinks, William, Olds & Cook, Ltd.

[57] ABSTRACT There is disclosed a machine for assembling, end capping, and packaging together in a preselected manner,

[ Aug. 20, 1974 per. The machine comprises a plurality of feed elements wherein each of the feed elements includes a receptacle for storing a plurality of rolls wherein the material on each of the rolls in any one feed element contains the same color and/or pattern of material I wrapped thereon. The feed elements individually feed the rolls contained therein onto a conveyor means. The conveyer means transports these rolls which are now arranged in a preselected color and/or pattern orientation to a grouping means which divides the rolls into a plurality of groups of rolls wherein each of the groups contain a preselected number of rolls having a preselected pattern and/or color distribution. This grouping means then feeds the group of rolls to an orienting means which acts upon the rolls in the group and orients the axial edge of the material wound on each of the rolls such that the axial edge is hidden from view within the package. Lastly, the group of rolls is then transported to a capping station wherein caps are placed over the end portion of the rolls to form a single package of rolls.

4 Claims, 23 Drawing Figures PATENTEMUSQU m4 3, 9 037' Zia 1. PACKAGING MACHINE BACKGROUND OF THE INVENTION The present invention relates to a packaging machine, and more particularly, to a packaging machine which automatically assembles a plurality of the rolls, aligns the axial edges of the material on each of the rolls, and places an end cap over the rolls to form a single package.

There has been a long felt need in the packaging industry to provide a machine which automatically packages together a plurality of rolls having material wrapped thereon into a single package. Heretofore, machines have been utilized to wrap or wind paper or other material around a hollow core to form a roll of such material. These machines are commonly referred to as rewinder machines. The function of the rewinder machines is to take larger rolls of material, such as paper, which may be approximately forty inches in diameter, and rewind this material onto smaller rolls having a l /1 inch or l /2 inch core. Once these smaller rolls have been prepared, it has been the general practice to place some type of adhesive or securing member around the edges to prevent the smaller rolls from unwinding. One machine developed for this purpose is disclosed in U.S. Pat. No. 3,523,402, issued on Aug. 1 l, 1970 to Willian S. West et al. and assigned to Cleo Wrap Corporation.

After the rolls have been banded by a banding machine, such as that disclosed in the West et al patent, the rolls are then manually sorted and grouped together to form individual packages. This type of packaging is very prevalent in the gift wrapping industry where a plurality of gift wrap rolls are packaged together in a single package and wherein each of the rolls in the package may be of a different color and/or pattern.

To make such a package, it has been the general practice for an individual to collect the rolls from a banding machine and place them together in a group. For example, if the desired package were to contain five rolls, an operator would select the desired five rolls and place them together and by hand place an openended container or end cap, on either end of the group of rolls to form the package. For aesthetic purposes, the operator would then rotate each of the rolls in the package such that the axial edge of the outer convolution of the material contained on the rolls would be hidden from view. After this has been done, the package would then be placed in a conventional over wrap machine wherein a plastic film would be placed over the entire package to form an aesthetically pleasing display package.

The present invention is designed to automate this latter process of collecting the rolls together in a preselected orientation, arranging the axial edges of the rolls such that they are not visible, end capping the group of rolls together to form a single package and then forwarding this package to a conventional over wrapping machine. As mentioned previously, a typical example of the use of the present invention would be in connection with gift wrapping papers which are wound on cardboard tubes or cores and which are packaged'together in packages containing for example, 2, 3, 5, or

2 even 12 rolls. It will be recognized, however, by one skilled in the art, that the present invention need not be limited to gift wrapping papers, and furthermore, that the size of the packages may be arranged in such a manner as to utilize any number of rolls within the package and that the rolls may be arranged in l, 2, 3, or any number of layers within the package without departing from the spirit or scope of the invention.

SUMMARY OF THE INVENTION The generalpurpose of this invention is to provide a packaging machine which is adapted to assemble, end cap, and package together in a preselected manner, a plurality of rolls having a material thereon wherein the color and/or pattern of the material on each of the rolls may be automatically arranged in any given orientation. To attain this, the present invention comprises a plurality of feed elements wherein each of the feed elements includes a receptacle for storing a plurality of rolls wherein the material on each of the rolls in any one feed element contains the same color and/or pattern of material wrapped thereon. The feed element individually feeds the rolls contained therein onto a conveyor means. The conveyor means transports these rolls which are now arranged in a preselected pattern and/or color orientation to a grouping device which divides the rolls into a plurality of groups of rolls wherein each of the groups contains a preselected number of rolls having a preselected pattern and/or color distribution. This grouping device then feeds the group of rolls to an orienting station which acts upon each of the rolls in the group and orients the axial edge of each of the rolls such that the axial edge is hidden from view within the group. Lastly, the group of rolls is then transported to an end capping station wherein end caps are placed over the end portion of the group of rolls, thereby forming a single package of rolls. This single package of rolls may be fed to a conventional overwrap machine wherein a plastic over wrapping may be placed over the entire package in a conventional manner.

In the preferred embodiment, the packaging machine of the present invention is utilized with rolls of Christmas gift wrapping paper, but it will be recognized that the invention is not limited thereto.

It is therefore an object of the present invention to provide a machine which can automatically wrap together as an individual package, a plurality of rolls having paper or other materials wound thereon.

Another object is to provide an apparatus for automatically orienting the axial edge of the outer convolution of a material wound upon a roll.

A further object is to provide an apparatus for automatically unfolding an initially folded container and placing the open end of the unfolded container over one end of the plurality of a group of rolls which are longitudinally grouped together.

Still another object is to provide an apparatus for assembling,

selected manner, a plurality of rolls wherein each of the rolls includes a material having a preselected color and-.

Yet another object is to provide a machine for auto matically packaging a group of rolls of Christmas gift wrapping paper together into a single package wherein end capping and packaging together in a preeach of the axial edges of the rolls of paper are hidden from view.

Other objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram showing an over all packaging system which utilizes the present invention.

FIG. 2 is a perspective view ofa roll having a material wound thereon and displaying the axial edge of the outer convolution of said material.

FIG. 3 is a perspective view of a portion of the machine constituting the preferred embodiment of the invention; namely, a grouping apparatus, an apparatus for orienting the axial edge of the material on each of the rolls, and an apparatus for end capping the group of rolls.

FIG. 4 is a side view of the remaining portion of the apparatus which constitutes the preferred embodiment of the invention; namely, a means for feeding a plurality of rolls having material wound thereon to the apparatus shown in FIG. 3.

FIGS. 5 and 6 are perspective views of a hopper mechanism which may be used to supply rolls of material to the apparatus shown in FIG. 4.

FIG. 7 is a perspective view of one of the feed hoppers shown in FIG. 4.

FIG. 8 is an enlarged side view of the synchronizing mechanism shown in FIG. 7.

FIGS. 9 and 10 are schematic views of an agitating device utilized in FIG. 7.

FIG. 11 is a side view of the grouping mechanism shown in FIG. 1.

FIGS. 12A and 12B are schematic views showing the operation of the grouping mechanism of FIG. 11.

FIGS. 13-15 are schematic views of a conveyor mechanism used to convey the group of rolls from the grouping mechanism of FIG. 11, and the tail orienting mechanism shown in FIGS. 2 and 18.

FIG. 16 is a schematic view of the orienting apparatus used to orient the axial edge of each of the rolls of material.

FIG. 17 is an enlarged side view of a portion of the apparatus shown in FIG. 16.

FIG. 18 is a schematic view of the fluidic system used in FIG. 16.

FIGS. 19 and 20 are perspective views of the apparatus for end capping each of the groups of rolls.

FIGS. 21 and 22 are diagrammatic views of a drive system utilized in the present invention.

Referring now to the drawings wherein like reference characters designate like or corresponding parts throughout the several views, there is shown in FIG. 1, a schematic diagram of an automatic packaging system 10 which may be used to produce rolls having material wound thereon and wherein these rolls may be automatically collected together to form a group of rolls and wherein these groups of rolls may be packaged together to form a single package or entity 36 (FIG. 3). A typical example of the use of the packaging system I0 disclosed herein would be in connection with gift wrapping papers which are wound on cardboard tubes or cores. In this regard, a typical package 36 would comprise a plurality of rolls 20, 20a, 20b, etc. which are longitudinally grouped together in one or more tiers or layers. An end cap 34 is normally placed on each end of the grouped rolls. Furthermore, when looking at the package 36, the axial edges of the material on each roll are normally not visible since they have been rotated towards the inner or hidden portion of the package 36. While the following description will refer to the use of the packaging system 10 in connection with gift wrapping paper, it will be recognized that the packaging system 10 has many other uses.

Referring to FIG. 1, the packaging system 10 comprises a plurality of conventional rewinder machines 12. The rewinder machine 12 is utilized to transfer material wound on large diameter rolls of material, for example, 40 inches in diameter, to a smaller roll wrapped around a smaller core, such as 1% inches to 1 /2 inches. These smaller rolls, such as the rolls shown in FIG. 2, are then conveyed by a transfer unit 14 to a conventional banding machine 16. Referring to FIG. 2, the roll 20 comprises a core 19 around which is wrapped or wound a material 21. The material 21 has an outer convolution 22 which in turn has an axial edge 17. The axial edge 17 is parallel to the longitudinal axis 23 of the core 19. The banding machine 16 is used to place a plurality of strips of heat shrinkable plastic film, hereinafter referred to as bands 18, around the roll 20. The bands 18 prevent the outer convolution 22 of the material 21 from unwinding thereby preventing movement of the location of the axial edge 17 with respect to the core 19. However, it will be recognized that by rotating the roll 20 about the longitudinal axis 23, the position or orientation of the axial edge 17 may be changed radially.

A typical banding machine which serves the purpose of banding the rolls 20 and which may be utilized in combination with the present invention is disclosed in US. Pat. No. 3,523,402, issued to William S. West et al. on Aug. 1 l, 1970 and assigned to Cleo Wrap Corporation. It will be recognized by one skilled in the art, however, that any type of banding apparatus may be utilized in place of the banding machine 16, and furthermore, if it is desired, the banding machine 16 may be replaced by anyof the conventional processes which heretofore have been used to prevent rolls of material from unwinding. I

As a plurality of rolls 20 are produced by the banding machine 16, they are conveyed to a hopper 24 (FIGS. 5 and 6). The hopper 24 may be placed at the discharge end 26 of the banding machine 16. As will be explained below, the hopper 24 is movably placed on a track 28. After the hopper 24 has been filled to capacity with rolls 20 from the banding machine 16, the hopper 24 is then conveyed via the track 28 to a staging area 30. At the staging area 30, each of the loaded hoppers 24 is held until they are needed. When it is desired to form packages containing a plurality of rolls 20, these filled hoppers 24 are then transmitted via the tracks 32, 32a, 32!; etc. to a packaging machine 40. The packaging machine 40 constitutes the preferred embodiment of the invention and will be disclosed in greater detail below.

The packaging machine 40 assembles into a package 36 (FIG. 3) a plurality of rolls 20, 20a, 201), etc. having material wrapped thereon wherein each of the rolls in the package 36 has a preselected color and/or pattern printed thereon. The packaging machine 40 collects a preselected number of these rolls 20 and orients the axial edge 17 of the outer convolution of material 22 on each of the rolls in such a manner as to hide this axial edge 17 from view by rotating each of said rolls about their longitudinal axis 23. Next, the packaging machine 40 places an end cap 34 over the ends of the groups of rolls which are longitudinally placed together (FIG. 3) within said end caps thereby forming the package 36. The package 36 is then fed to a conventional over wrap machine 38 wherein a heat shrinkable plastic is placed around the entire package 36. This package 36 contained in the plastic over wrap is then conveyed to a conventional shrink tunnel 39. The shrink tunnel 39 shrinks the plastic around the package thereby forming an aesthetically pleasing marketable package of wrapping apper. Each of these packages is .then collected in a conventional manner and may be stored or placed in a carton or the like.

As mentioned above, the packages 36 each contain a plurality of rolls 20a, 20b, 20c, etc. (FIG. 3). It is normally desirable to be able to selectively choose the color and/or pattern which is tobe placed on each of the rolls and to always place that particular color and- /or pattern in the same location relative to the other rolls in the package 36 so that every package 36 would be identical. The packaging system enables this arrangement of rolls to be done automatically. Again referring to FIG. 1, let us assume that the rewinder 12 contains a material which is blue in color. This blue material is then wound onto smaller rolls by the rewinder thereby forming a plurality of rolls which are stored in a given hopper 24. Let us also assume that a second rewinder 12a is used to rewind material having a red color onto rolls thereby forming a plurality of red rolls a which are stored in a second hopper 24a. Similarly, a third rewinding unit 12b may be used to form green rolls 20b which are stored in a third hopper 24b. It will be recognized that an endless variety of patterns and/or colors may be wound on rolls and these rolls stored in hoppers. While FIG. I only discloses four rewinder units, it will be recognized that any number may be utilized and that any number of hoppers may be utilized to store these individually segregated rolls.

Now let us assume, that it is desirous to form a package 36 containing three rolls therein; 20, 20a and 20b. And let us also assume that it is desirous that the first roll in the group be a blue roll 20; the second roll, a red roll 20a; and, the third roll, a green roll 20b. By an appropriate signal, three hoppers 24, 24a and 24b are directed from the staging area to the packaging machine 40. The hopper 24, containing only blue rolls 20, will travel along the track 32 to a collection area 42. Similarly, the hopper 24a, containing only red rolls 20a, will travel along the track 32a to a collection area 42a, and the hopper 24b, containing only green rolls 20b, will travel along the track 32b to a collection area 421). Any number of collection areas may be provided. For example, if it is desirable to have twelve rolls in the package, then twelve such collection areas will be provided. One such packaging machine having twelve collection areas is shown in FIG. 1 and is given the designation 40a or 40b. It will also be noted that any number of packaging machines 40, 40a, 40b maybe utilized in tandum and that the track 32, 32a, 32b, etc. may be used to feed each of these packaging machines 40, 40a and 40b. In this manner, a plurality of groups of packages may be formed simultaneously. For clarity, the

discussion below concerning the packaging machine will only deal with a single packaging machine 40.

However, it will be recognized that a plurality of packaging machines 40, 40a, 40b, etc. may be utilized together thereby increasing productivity.

Referring now to FIGS. 3 and 4, the packaging machine 40 may be seen in greater detail. The packaging machine 40 comprises a plurality of feed stations 42, 42a, 42b, etc. which comprise the entrance to a plurality of feed hoppers 44, 44a, 44b, etc. Each of the feed hoppers 44, 44a, 44b, etc. includes a receptacle area 46, 46a, 4612, etc. wherein a plurality of rolls 20 may be stored. In addition, each feed hopper 44 also includes a feeder mechanism or synchronizing device 48 which is adapted to feed one roll at a time from each receptacle onto an endless conveyor 50. As the rolls from the feed hoppers 44, 44a, 44b sequentially drop onto the conveyor 50 they are conveyed to the left as shown in FIG. 4 towards a grouping apparatus 60. Again referring to FIG. 4, it will be noted that a second endless conveyor 52 is also provided. Endless conveyor 52 is similar in function to endless conveyor 50. The function of each of the conveyors 50 and 52 will become clear below. Briefly, the endless conveyor 50 is adapted to receive rolls from a first group of feed'hoppers 44 to Me while the second endless conveyor 52 is adapted to receive rolls from a second group of feed hoppers 44f to 44k. In this manner, it is possible to ultimately form a two-layer package of rolls. If only a single layer package of rolls is desired, it is only necessary to provide a single endless conveyor 50. Similarly, if a triple tier or layer package is desired, then a third conveyor should be provided vertically spaced from the first and second conveyors. Furthermore, it will be recognized by one skilled in the art that while only twelve feed hoppers are shown, any number of feed hoppers may be utilized and furthermore, if it is desired to manufacture only a single tier package, it is not necessary to eliminate the second belt, but by merely filling those hoppers which feed to one conveyor, e.g., 44 to 44e, or the other conveyor (44f to 44k), a single tier package 36 may be manufactured.

Again referring to the original example of using three different colored rolls, blue, red and green, it will be seen that as the feed hopper 44 places a blue roll on the endless conveyor 50 the second feed hopper 440 places a red roll on the endless conveyor 50 and the third feed hopper 44b places a green roll on the endless conveyor 50, you have three rolls arranged parallel to each other traveling at a direction transverse to the longitudinal axis 23 of each of the rolls. These rolls proceed along the endless conveyor 50 to the grouping apparatus more clearly seen in FIGS. ll, 12, 12A and 128.

The grouping apparatus 60 comprises a pair of infeed chutes 62 and 62a. The infeed chute 62 receives the rolls from the first endless conveyor 50 while the second infeed chutes 62a receives the rolls contained on the second endless conveyor 52. A pair of barriers 64 and 66 are provided. These barriers are adapted to block the path of the infeed chutes 62 and 62a. The spacing of the barrier 64 from the barrier 66 enables one to selectively group a preselected number of rolls. For example, referring to FIG. 12a, the first barrier 64 is raised such that rolls 20, 20a, 20b, etc. may slide down the infeed chute 62 while the second barrier 66 is lowered thereby blocking further passage of the rolls. It will be noted that the spacing between the first barrier 64 in a first position and the second barrier 66 in a second or closed position allows six rolls to enter the space therebetween. After the first preselected number of rolls, for example, six, have filled the space between the first barrier 64 and the second barrier 66, the first barrier 64 is then moved into its second or closed position as shown in FIG. 12b while'the second barrier 66 is moved into the first or open position, thus enabling the preselected group of rolls, namely, 20, a, 20b, 20c, 20d and 20e to pass down the infeed chute 62 towards a holding station 68. The holding station 68 in the preferred embodiment also comprises a pair of guide channels 70 and 70a which may be continuations of the infeed chutes 62 and 62a. At the holding station 68, a pair of holders 72 and 74 are conveyed in front of and behind the rolls which had been grouped by the grouping apparatus 60, such as shown in FIGS. 13 and 14. These preselected number of rolls are held together as a single group by the holders 72 and 74. As shown in FIGS. 13, 14 and I5, and will be explained below, these holders, as well as the rolls, are conveyed along another endless conveyor 7 towards a tail orienting station 80 (FIGS. 3 and 16). It will be recognized that while FIG. 11 discloses two chutes 62 and 62a, that if only a single conveyor 50 is provided, it is only necessary to have a single chute 62. Similarly, ifa third conveyor is vertically spaced from the conveyors 50 and 52, it will then be necessary to utilize a third chute as part of the grouping apparatus 60.

Referring to FIGS. 3, 16 and 17, the tail orienting apparatus 80 will be seen. The tail orienting apparatus 80 is utilized to radially orient the position of the axial edge 17 (FIG. 2) of the outer convolution of material 22 wound upon each roll 20 in such a manner as to locate this axial edge in a preselected orientation with respect to each of the other rolls within the finished package 36. In the preferred embodiment, it is desirable to orient this axial edge 17 in such a manner so as not to be visible from the outside, the completed package 36 (shown in FIG. 3). However, any other orientation is also possible. (The method whereby the tail orientation apparatus 80 orients the axial edges 17 will be explained in detail below). After each of the axial edges 17 has been oriented by the tail orienting apparatus 80, the entire group of rolls which had been originally grouped together by the grouping apparatus 60 are then conveyed by the holders 72 and 74 to an end capping apparatus 100 (FIGS. 3, 19 and 20). At the end capping station 100, a pair of initially folded end cap containers 34, each of the containers having at least one open end, are removed from a supply of those containers, are opened, and are placed on each end of the grouped rolls. The rolls are initially compressed by a squeezer arm 112 and while the end cap 34 is placed thereon and then after the compressing means is released, the end containers or end caps 34, then hold the rolls together in a group. After these rolls have been held together to form the package 36 as shown in FIG. 3, they are then passed by a suitable conveyor means 104 to a conventional over wrap station as shown in FIG. 1. Thus, the packaging machine 40 when used as part of the packaging system 10, allows for the complete packaging of a plurality of rolls into a neat uniform package without the need for human manipulatron.

Now, referring to the drawings, the packaging machine 40 will be described in greater detail. Referring to FIGS. 1, 5 and 6, it can be seen that banded rolls, such as the rolls 20 shown in FIG. 2, are received by the hopper 24 from the discharge end 26 of the banding machine 16. The hopper is located upon the track 28 as shown in FIG. 6, and is adapted to be conveyed along the track 28 which interconnects to the tracks 32, 32a, 32b, etc. in a well-known conventional manner. A separate hopper 24 is provided at the discharge end of each of the banders 16, 16a, 16b and 160, and by well-known selection methods, one is able to control the movement of each of these hoppers 24 individually and send them to the correct location in the staging area 30. As the rolls are dropped into any of the hoppers 24 from their associated banding machine 16, the number of rolls being dropped therein may be counted by any suitable counting device such as an electric eye counter. After a preselected number of rolls are dropped into the hopper 24, a signal is given which transports the hopper away from the banding machine 16 and places it into a preselected position in the staging area 30. An empty hopper 24 is then placed at the discharge end 26 of that previous banding machine. The rolls produced from the banding machine 16 while the full hopper is being removed and the empty hopper is being replaced, may be held in a chute (not shown) until the empty hopper 24 again gets to the discharge end. At this time, the rolls are released into the empty hopper and continues to drop into the empty hopper 24 until the desired number of rolls is again attained.

In the preferred embodiment, the hopper 24 comprises a container having a trap door type release 25. The trap door may be opened remotely in a conventional manner or may be opend by a latch or a lever 27 designed to open the trap doors 25 at a preselected signal.

The full hopper 24 is carried from the discharge end 26 of the banding machine 16 to the staging area 30 wherein it awaits a signal from the feed hopper 44. As mentioned above, each of the hoppers 24 contains a plurality of rolls 20 having a material of a given color and/or pattern contained therein and these hoppers are then selectively conveyed to a particular feed hopper 44 which is used to place these rolls in a preselected manner on the endless conveyors 50 or 52. Referring now to FIGS. 7-10, in conjunction with FIG. 4, the operation of the feed hoppers 44 will become clear. As shown in FIG. 7, which is representative of one of the individual feed hoppers 44, there is a funnel shaped receptacle 46. Connected to the lower end of the funnel shaped receptacle 46 is a guide channel 54. The guide channel 54 insures only one roll at a time is fed to the conveyors 50 or 52. When the number of rolls in the receptacle 46 is reduced to a certain preselected level, a signal is given to the hopper conveying system to bring another loaded hopper 24 into position above the receptacle 46. Once the hopper is above the receptacle 46, a latch release mechanism 45 actuates the lever 27 on the hopper 24 (FIG. 5) and opens the trap doors 25 releasing the rolls 20 into the receptacle 46. The empty hopper 24 then proceeds back towards the banding machine 16 to collect additional rolls.

The rolls 20 within the receptacle 46 are fed by gravity through the guide channel 54 towards the synchronizing or feeder mechanism 48. The synchronizing mechanism 48 which is shown in greater detail in FIG. 8, receives rolls from the guide channel 54 and conveys them, one at a time, to either the conveyor 50 or the conveyor 52. The primary purpose of the synchronizing mechanism 48 is to provide the proper separation required between each of the rolls 20 as they are dropped onto conveyor 50 or 52. As can be seen in FIGS. 4 and 7, the speed of movement of the conveyors 50 and 52 are interrelated with the speed of rotation of the synchronizing mechanism 48 and this is done by a drive train 58 taken off the main drive train 59 for the conveyors 50 and 52.

The synchronizing or feeder mechanism 48 in the preferred embodiment comprises a paddle or star type feeder. The rolls 20 pass through the guide channel 54 onto one of a plurality of holders 49, which move in a vertical rotating manner with respect to the conveyors 50 and 52. As a roll leaves the guide channel 54 it is caught by the holder 49 which conveys it around the synchronizing mechanism 48 and eventually into a chute 51. The chute 51 drops the rolls 24 onto either the conveyor 50 or the conveyor 52.

It has sometimes been found that when a funnel-feeding mechanism is utilized, it is desirable to provide an agitator or separator 56 adjacent to the smaller end of the funnel like opening of the receptacle 46. The agitator 56 prevents the rolls from jamming at this opening and ensures that only one roll at a time passes through the guide channel 54, thereby ensuring the proper functioning of the synchronizing or feeder mechanism 48.

As mentioned previously, the number of feed hoppers 44 is optional and the packaging machine 40 may contain the same number of hoppers as the desired maximum number of rolls in any given package. By utilizing two conveyors 50 and 52 on two different levels, a multi-level or layered package 36 may be obtained and proper color and pattern orientation of the rolls may be developed.

Again, referring to FIG. 4, each of the synchronizing members 48, 48a and 48h, drops a roll simultaneously onto either the conveyor 50 or the conveyor 52 and thus, the proper sequencing of the rolls may be obtained and the sequencing is consistant throughout the entire operation. As the conveyors 50 and 52 convey the rolls, the rolls 20 go to the grouping apparatus 60 through the infeed chutes 62 and 62a, shown in FIGS. 3, 12, 12A and 12B. In the infeed chutes 62, and 62a, the rolls are collected and divided into the preselected quantity required for the individual package make up. In the preferred embodiment, this is done by the pair of barriers 64 and 66 which are pneumatically controlled cylinders. However, it will be recognized that other types of barriers and/or barrier controls may be utilized. As the two rear cylinders 64 open, gravity feeds the rolls forward towards the second or forward barrier 66. Because the barrier 66 is closed, this stops the rolls from passing on into the tail orienting apparatus 80. After the proper number of rolls is between the barriers 64 and 66, the rear barrier 64 is closed, the front barrier 66 is opened, thereby allowing a preselected number of rolls to pass down the infeed chutes 62 and 62a towards the holding station 68.

At the holding station 68, the roll holders 72 and 74 take hold of the preselected group of rolls as clearly shown in FIGS. 13 and 14. These holders 72 and 74 now remainwith this preselected group of rolls until the rolls are end capped by the end capping apparatus 100. The conveyor 76 (FIGS. 3 and upon which the holders 72 and 74 are mounted, conveys the group of rolls towards the tail orienting apparatus 80.-Referring to FIGS. 21 and 22, the conveyor drive system for the conveyor 76 becomes apparent and will be explained below.

The group of rolls which were grouped together by the grouping mechanism 60 and held together by the holders 72 and 74 are indexed by the conveyor 76 to the tail orienting station 80. The groupof rolls, as shown in FIGS. 3 and 16, are placed between a pair of movable plates 82. The movement of the pair of plates is controlled by a drive mechanism described later, and is adapted to move inwardly and outwardly axially with respect to the rolls. As will be explained below, the plates 82 move towards the group of rolls between them. Mounted upon one plate 82 is a plurality of spindle drives 84. One spindle drive 84 is provided for each roll 20 contained within the group. On the second plate 88, an idler spindle 86 is provided. The spindle drive 84 in conjunction with the idler spindle 86 is adapted to rotate the rolls between the two spindles 84 and 86 thereby effectuating the orientation of the axial edge 17 of the outer convolution of material wound thereon 1 by rotating the roll 20 about its longitudinal axis. When the group of rolls passes between plates 82, the pair of plates 82 begin to move inwardly. The inward movement of the plates 82 causes the plates to actuate a switch 85. As will be explained with reference to FIG. 16, the actuation of the switch thereby energizes a motor 87 and causes the spindle drives 84 to begin to rotate. The drive spindle 84 and the idler spindles 86 engage the rolls during the last portion of inward travel of the side plates 82 and due to the spring load take up of the idler spindles 86, they are able to start turning the rolls before the side plates reach the limit of their inward travel.

Upon reaching the limit of travel, one side plate 82 actuates a second switch which in turn, energizes, as will be explained in reference to FIG. 18, a plurality of sensors 88. It is important that the rolls 20 are each rotating prior to the energization of the sensors 88.

One sensor 88 is provided for each roll 20 which is to be rotated by the drive spindles 84. The sensors 88 are used to sense the location of the axial edge or tail of each of the rolls 20 within the group. The sensors 88 are energized when the side plates 82 actuate the switch 90. When an axial edge of a revolving roll 20 strike in respective sensor 88, a signal is generated by the sensor 88. This signal causes the spindle for this roll to brake as diagrammatically represented by a brake pad 83 in FIG. 17. The position of each sensor 88 is arranged such that the axial edge 17 of the roll will be in the prselected desired radial location when it comes in contact with its respective sensor 88. Thus, it will be recognized that depending upon the positioning of the sensors 88, the axial edge 17 of each roll 20 may be located in any preselected radial position.

After each of the spindles have braked, the entire group of rolls between the spindles 84 will have had their axial edges oriented. The side plates then retract outwardly to their original positions and the groups of rolls is then indexed by the conveyor 76 and the holders 72 and 74 to the end capping apparatus 100.

In the preferred embodiment of the invention, the sensors 88 are air actuated and controlled Norgren feather flex sensors No. SSF 010-00, and therefore the entire control for the tail orienting apparatus 80 is also pneumatically controlled. It will be recognized, however, that other types of sensors may be utilized as well as other non-pneumatic controls.

Referring now to FIG. 18, a fluidic control system 200 for the tail orienting apparatus 80 will be described. A source of air 202 provides air through a filter 204. The air is separated into three air streams of three different pressures by a plurality of air regulators 206, 208 and 210. The air regulator 206 provides a l3 p.s.i. module pressure; the air regulator 208 provides a 6 p.s.i. supply signal pressure; and the regulator 210 a 50 p.s.i. cylinder pressure. The signal from the regulator 208 is further divided to provide an air supply to each feather flex sensor 88 via a conduit 212. Another air supply is provided via the conduit 214 to a plurality and/or FLIP FLOP modules 216 while an air signal is provided via a conduit to 218 to each of the modules 216. In the preferred embodiment, the module 216 comprises a Norgren and/or FLIP FLOP Module No. 4CF-2 10-000.

The control system 200 is designed so that the system is energized by the side plate 82. As soon as the side plates 82 begin to move inwardly, it causes a valve 222 to send a signal via conduit 214 to the module 216 which in turn sends a signal to the valve 226 to send an air supply of 50 lbs. pressure from regulator 210, to the cylinder 228, this in turn starts the spindles 84 to rotate.

As the plates 82 continue moving inwardly, they cause a second valve 220 to send a signal via conduit 218 to module 216 readying the module 216 to receive a signal from the sensor 88. In addition, a constant l3 p.s.i. air supply is also provided to the module 216 by the conduit 224. When the module 216 is signalled, it sends a 13 p.s.i. air signal to the pilot side of a valve 226. The l3 p.s.i. signal is the amount of pressure required to operate the preferred valve 226. In addition, a 6 p.s.i. supply is constantly provided to the input side of each sensor 88 by the conduit 212.

When the roll rotates, and the axial edge 17 contacts the sensor 88, this opens the inlet into the sensor and sends the 6 p.s.i. signal from the sensor 88 to the module 216. When the module 216 receives this signal, it opens the way for the 13 p.s.i. supply to pass through the module 216 and sends a signal to the valve 226. This signal shifts the valve 226 to the closed position stopping the 50 p.s.i. pressure from the regulator 210 to the cylinder 228 (see also FIG. 17). The cylinder 228 is adapted to deactivate the brake 83 thereby starting the rotation of the drive spindles 84.

When the side plates move outwardly, they release the signal valve 220 cutting off the air supply to the module 216; thus, not letting it receive a signal from the sensors 88 when the next group of rolls enter the tail orientation station 200.

It will be recognized that ifa greater number of drive spindles 84 are provided than there are rolls, the control system 200 allows for the respective modules 216 to be deactivated by a switch 230 thereby disabling the drive spindle 84. While the control system 200 has been described using specific valves and components, it is to be emphasized that these valves are only representative and other valves and components may be utilized. It is also to be recognized that one module 216, valve 226 and cylinder 228 is provided for each drive spindle 84.

Returning now to FIGS. 3, I9 and 20, the final portion of the packaging machine 40 will be described.

After each of the rolls 20 have had their axial edge 17 oriented in a preselected location, the entire group of rolls is indexed via the conveyor 76 to the end capping station 100. In the preferred embodiment, the end capping station as shown in FIG. 3 for simplicity is also connected to the side plates 82. After the group of rolls indexes to the end capping station 100, the side plates 82 move inwardly and bring a container 34 which has already been opened. Simultaneously, a separator I06 removes an unfolded container 34 from the stack of those containers and brings it into a position for opening. It is then held in place while the side plates 82 move outwardly towards the right as shown in FIG. 20. After the side plates 82 go out, the end cap opener cylinder 108 closes onto the folded cap 34 and a pair of vacuum cups 110 grab the container 34 and open it as the opener cylinders 108 return to their original up position. The side plates 82 then come in bringing the open cap 34 over the package of rolls. Simultaneously, the package of rolls are being compressed by a pair of squeezer arms 112. The vacuum is then cut off leaving an open container 34 on the end of the group of rolls and letting the side plates return outwardly. In this manner, the open container 34 is now frictionally engaged to the end portion of the group of longitudinally grouped rolls forming a package 36. This entire package 36 of longitudinally grouped rolls is then conveyed via a conventional conveyor 104 (FIG. 3) to an over wrap station.

It is clear from FIGS. 3 and 4 that the movement of all members of the packaging apparatus 40 must be synchronized. In this regard, one method for driving the conveyors 50, 52 and 76 and synchronizing the movement of these conveyors with the movement of the side plates 82 is shown in FIGS. 21 and 22. A main drive train 59 (FIG. 4) is provided to drive the conveyors 50 and 52. This is a continuous drive in the preferred embodiment; however, an indexing drive may also be used. The conveyor 76 is driven by an indexing drive 138 which may be powered from the main drive 59. The indexing drive 138 comprises an electric motor 140 with an air clutch 142 attached to the drive shaft. The air clutch 142 is operated by a valve controlled by a microswitch as shown in FIG. 22 and uses a form sprag 143 for returning to the original position. This allows the air clutch 142 to drive one revolution or 360 for each cycle, giving a slow start, up to maximum travel speed then slowing down to a stop. This makes the indexing of the conveyor 76 a smooth operation. The sequence of operation of the drive for the conveyor 76 will now be explained. First, the motor 140 is turned on and then if required, the vacuum motor tail orienting motor 87 (FIG. 16) is also turned on. Next, the control or automatic cycle switch is actuated to signal the air clutch 142 to engage the start of the indexing cycle for the conveyor 76. As the crank arm or connection arm 144 rotates with the clutch 142 and drive, it first hits a microswitch 146 that signals the vacuum cap opener cylinder 108 to close upon the folded container 34. The second switch 148 signals the package compression arms 112 to squeeze the package 36 of rolls 20 and also the vacuum cap opener cylinders 108 to open the folded container 34. The third switch 85 (FIGS. 16 and 22) causes the side plates 82 to come in for end capping and tail orientation. A fourth switch 90 (FIGS. 16 and 22) located at the outermost position of the side plates 82, gives a signal to supply current to a conventional timer (not shown) which starts a timing cycle. At the endof the timing cycle a signal is given for the side plates 82 to return to their out position and cut the vacuum supply off at the end cap cylinders 108. The crank arm and switch actuator 144 then hits a fifth switch 150 which causes the clutch 142 to disengage. Upon the return of the side plates 82 to the out position, the fourth switch being closed, then turns off current to the timer and re-energizes the automatic cycle switch or control and also turns the vacuum supply back on to the end capping opening cylinder 108. Thus, recycling the entire operation and indexing another group of rolls to.

the tail orienting station 80 tion 100.

In summary, the packaging machine 40 which constitutes the preferred embodiment of the invention, is able to group together a plurality of rolls automatically, orient the axial edge of the material wound upon the roll to a preselected location, and then place a container over the ends of the package to form a compact aesthetically pleasing group of package of rolls having any preselected number and orientation therein. Obviously, many modifications and variations of the present invention are possible in light of the above teaching and it should be understood, of course, that the foregoing disclosure relates only to a preferred embodiment of the invention and that numerous modifications or alterations may be made therein without departing from the spirit and the scope of the invention as set forth in the appended claims.

What is claimed is:

1. An apparatus for automatically unfolding an initially folded container, said container having at least one open end, and for placing said open end of said unfolded container over one end of a plurality of rolls which are longitudinally grouped together; comprising:

and to the end capping sta' means for selecting and removing a folded container from a supply of said folded containers and conveying said selected container to an end capping station.

vacuum means located at said end capping station wherein a vacuum is formed in response to a first signal and wherein said vacuum means thereby opens said folded container;

means for conveying said plurality of longitudinally grouped rolls to said end capping station;

means for placing said open end of said unfolded container over one end of said longitudinally grouped rolls; and

means responsive to a second signal for releasing said vacuum thereby enabling said opened container to engage said longitudinally grouped rolls.

2. The apparatus of claim 1 further comprising a means for compressing said longitudinally grouped rolls prior to said unfolded container being placed thereon and wherein said compressing means is released when said container has been placed over one of said ends of said grouped rolls.

3. The apparatus of claim 1 further comprising a guide means for ensuring that said container is placed securely around said end of said plurality of grouped rolls.

4. An apparatus for automatically end capping two ends of a plurality of rolls which are longitudinally grouped together, comprising:

a pair of means for selecting, removing, and conveying a folded container from a supply of folded containers, wherein said folded containers each include at least one open end, to an end capping station;

a pair of vacuum means located at said end capping station wherein a vacuum is formed in response to a first signal and wherein each of said vacuum means thereby opens one of said selected folded containers;

means for conveying said plurality of longitudinally grouped rolls to said end capping station wherein said group of rolls are located between said pair of vacuum means;

means for compressing said rolls and for placing said open end of one of said unfolded containers over a first end of said group of rolls and the second of said unfolded containers over a second end of said group of rolls; and

means responsive to a second signal for releasing said vacuum formed by each of said vacuum means and for releasing said compressing means thereby enabling said open ended containers to engage the end portion of said longitudinally grouped rolls. 

1. An apparatus for automatically unfolding an initially folded container, said container having at least one open end, and for placing said open end of said unfolded container over one end of a plurality of rolls which are longitudinally grouped together; comprising: means for selecting and removing a folded container from a supply of said folded containers and conveying said selected container to an end capping station. vacuum means located at said end capping station wherein a vacuum is formed in response to a first signal and wherein said vacuum means thereby opens said folded container; means for conveying said plurality of longitudinally grouped rolls to said end capping station; means for placing said open end of said unfolded container over one end of said longitudinally grouped rolls; and means responsive to a second signal for releasing said vacuum thereby enabling said opened container to engage said longitudinally grouped rolls.
 2. The apparatus of claim 1 further comprising a means for compressing said longitudinally grouped rolls prior to said unfolded container being placed thereon and wherein said compressing means is released when said container has been placed over one of said ends of said grouped rolls.
 3. The apparatus of claim 1 further comprising a guide means for ensuring that said container is placed securely around said end of said plurality of grouped rolls.
 4. An apparatus for automatically end capping two ends of a plurality of rolls which are longitudinally grouped together, comprising: a pair of means for selecting, removing, and Conveying a folded container from a supply of folded containers, wherein said folded containers each include at least one open end, to an end capping station; a pair of vacuum means located at said end capping station wherein a vacuum is formed in response to a first signal and wherein each of said vacuum means thereby opens one of said selected folded containers; means for conveying said plurality of longitudinally grouped rolls to said end capping station wherein said group of rolls are located between said pair of vacuum means; means for compressing said rolls and for placing said open end of one of said unfolded containers over a first end of said group of rolls and the second of said unfolded containers over a second end of said group of rolls; and means responsive to a second signal for releasing said vacuum formed by each of said vacuum means and for releasing said compressing means thereby enabling said open ended containers to engage the end portion of said longitudinally grouped rolls. 